Turbofan Vane Coating Apparatus with Movable Covering Body
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Solution Overview
Problem
Conventional anti-erosion coating methods for turbofan engine vanes result in a height difference between the metal sheath and the paint layer, leading to pressure loss and adverse aerodynamic performance due to the use of masking tapes.
Innovation Solution
A vane coating apparatus with a movable covering body and a control unit that transitions between sheath cladding and finish coating modes, ensuring even paint application and minimizing height differences by covering and uncovering the metal sheath's lateral edge portions during the coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If masking tapes are used to cover lateral edge portions of the metal sheath during paint application, then the metal sheath is protected from paint coverage, but a height difference is created between the metal sheath and paint layer
Solution Approach 1:
A movable covering body is introduced as an intermediary tool between the masking tape and the paint spray. This covering body has a shape that matches the lateral edge portion of the metal sheath, allowing it to cover the boundary portion precisely during paint application. The covering body can be moved to and from the boundary portion, enabling controlled paint application that prevents height difference formation while maintaining ease of coating operation.
2Reliability
If paint is applied thickly over the entire vane surface including boundary portions, then complete coverage is achieved, but aerodynamic performance deteriorates due to height differences
Solution Approach 1:
The coating thickness is made non-uniform in a controlled manner: the movable covering body prevents paint from accumulating at the boundary portion between the metal sheath and vane surface, while allowing normal paint application on the main vane surface. This creates a local quality difference where the boundary portion has minimal paint thickness (matching the metal sheath level) and the vane surface has the required protective coating thickness, thus maintaining both coating coverage and aerodynamic performance.
3Productivity
If masking tapes are removed after painting, then the coating process is complete, but correction work becomes indispensable to fix height differences
Solution Approach 1:
The movable covering body performs the protective function in advance during the paint application process itself, preventing paint from accumulating at the boundary portion before the problem manifests. This preliminary protective action eliminates the need for subsequent correction work that would otherwise be required after masking tape removal, thereby maintaining high productivity while simplifying the overall manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents height differences that could affect aerodynamic performance by precisely controlling paint application, ensuring a uniform coating and reducing pressure losses.
Implementation Method 1
a nozzle (4) for spraying paint onto a vane surface of the vane body except for the metal sheath of the vane supported by the jig (10)
Data Source
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AI summary
To prevent a height difference from being produced between a metal sheath and a paint layer formed on a vane surface of a vane body. A coating apparatus includes a jig (10) adapted to support a guide vane (V) equipped with a metal sheath (S) for covering a leading edge portion (LE); a nozzle (4) adapted to spray paint onto a vane body (Va); a robot (5) adapted to move the nozzle; and a control unit (6) adapted to control a spraying operation of the nozzle (4) and robot (5). The jig (10) includes a movable covering body (15) adapted to separably cover the metal sheath (S) and cover an exposed portion (Ta) of adhesive between a lateral edge portion (Sr) of the metal sheath (S) and the vane surface (Vd) of the vane body (Va), and a covering body drive unit (20) adapted to move the movable covering body (15) between a state in which the movable covering body (15) covers the metal sheath (S) and a state in which the movable covering body (15) is separated from the metal sheath (S) while covering the metal sheath (S). The control unit (6) performs control to make transition from a sheath cladding coating mode to a finish coating mode.